Method of forming a phase change thermal interface material

ABSTRACT

A thermal interface material (A) transfers heat from a heat source ( 12 ), such as a microprocessor, to a heat sink ( 14 ) for maintaining the microprocessor at a safe operating temperature. The interface material includes thermally conductive filler particles dispersed in a phase change material. The phase change material softens and flows at the operating temperature of the heat source, thereby providing good thermal contact with uneven surfaces of the heat source and heat sink, without excessive exudation and loss of the interface material. The phase change material includes a polymer component, such as an elastomer, and a melting point component, which adjusts the softening temperature of the phase change material to the operating temperature of the heat source.

[0001] This application claims priority from U.S. ProvisionalApplication Serial No. 60/142,751, filed Jul. 8, 1999.

BACKGROUND OF THE INVENTION

[0002] This invention pertains to thermally conductive materials, andmore particularly, to a thermally conductive interface material for heatgenerating devices, such as microprocessor power supply assemblies, thatfacilitates heat transfer from the heat generating device to a heatsink.

[0003] With increasing market pressure for smaller, faster, and moresophisticated end products using integrated circuits, the electronicsindustry has responded by developing integrated circuits which occupyless volume, yet operate at high current densities. Power supplyassemblies for such microprocessors generate considerable heat duringoperation. If the heat is not adequately removed, the increasedtemperatures generated by the power supply assemblies will result indamage to the semiconductor components.

[0004] A heat sink is commonly used to transfer the heat away from thepower supply or other heat generating assembly. The heat sink generallyincludes a plate or body formed from a conductive metal, which ismaintained in thermal contact with the assembly for dissipating heat inan efficient manner. Fins optionally protrude from the plate forproviding an increased surface area for heat dissipation to thesurrounding environment.

[0005] The current industry technique for providing thermal contactbetween a microprocessor power supply assembly and a heat sink is tointerpose a thermal interface material between the two, whichfacilitates heat transfer from the active device to the heat sink.

[0006] One method is to apply a ceramic filled thermal grease, which istypically silicone based, between the heat sink and the power supply.Thermal greases provide excellent thermal properties, but require anextensive assembly process with high manufacturing cost. The product isusually applied by hand, from a syringe, or with an aluminum carrier.This process is labor intensive and slow and does not lend itself toautomation.

[0007] Another method for providing a conductive interface includes theuse of thermally conductive wax compounds. These compounds, however, aregenerally brittle at ambient temperatures and easily chipped off,resulting in a high thermal resistance. The low viscosity of the wax atoperating temperature causes the wax to flow out from between the activecomponent and the heat sink, resulting in a high thermal resistance.Further, because of the brittle nature of the wax compounds, they aredifficult to manufacture and apply to a heat sink.

[0008] Thermally conductive silicone rubbers have also been used asconductive interfaces. Although soft and pliable, the silicone rubberrequires relatively high pressure and a long warm-up time to attain alow thermal resistance. The rubbers have poor flow characteristics whichresult in a low thermal conduction when there is a mismatch of flatnessbetween the heat sink and the heat producing device. Differences in thethermal coefficient of expansion between the silicone rubber and theheat sink can result in high thermal resistance during temperaturecycling. These effects lead to a poor thermal conductivity from the heatproducing device to the heat sink.

[0009] Other thermal interfaces employ polymeric thermally conductivecure-in-place compounds. These compounds are generally rigid after cure.They have a poor reliability because of a difference in thermalcoefficient of expansion between the material and the heat sink, causingcracks and failure during temperature cycling. The polymeric materialsare labor intensive to apply and require long cure times.

[0010] The present invention provides for a new and improved thermalinterface which overcomes the above-referenced problems and others.

SUMMARY OF THE INVENTION

[0011] The present invention relates to a thermal interface materialwhich can be easily pre-attached to a microprocessor power assembly or aheat sink prior to shipment.

[0012] In accordance with one aspect of the present invention, a thermalinterface material, which undergoes a phase change at microprocessoroperating temperatures to transfer heat generated by a heat source to aheat sink, is provided. The thermal interface material includes a phasechange substance, which softens at about the operating temperature ofthe heat source. The phase change substance includes a polymer componentand a melting point component. The melting point component modifies thetemperature at which the phase change substance softens. The thermalinterface material further includes a thermally conductive fillerdispersed within the phase change substance.

[0013] In accordance with another aspect of the present invention, amulti-layer strip is provided. The strip includes a layer of a thermalinterface material for thermally connecting a heat source with a heatsink. The thermal interface material includes a polymer component, amelting point component in sufficient quantity to adjust the softeningtemperature of the interface material to about the operating temperatureof the heat source, and a thermally conductive filler mixed with themelting point component and the polymer component. The strip furtherincludes an outer layer disposed on a side of the thermal interfacematerial. The outer layer includes at least one of a protectivereleasable liner and a layer of an adhesive material.

[0014] In accordance with another aspect of the present invention, amethod of providing a thermal interface between a heat source and a heatsink is provided. The method includes interposing a thermal interfacematerial between the heat source and heat sink, which softens at aboutthe operating temperature of the heat source to provide a thermalinterface between the heat source and the heat sink during operation ofthe heat source. The thermal interface material includes a polymercomponent, a melting component for modifying the temperature at whichthe thermal interface material softens, and a thermally conductivefiller mixed with the polymer component and the melting point component.

[0015] One advantage of the present invention is that the thermalinterface material can be pre-attached to a heat sink prior to shipment.

[0016] Another advantage of the present invention is that the cohesivestrength and integrity of the thermal interface material provide foreasy handling.

[0017] Still another advantage of the present invention is that thethermal performance of the thermal interface material matches that ofthermal grease in a solid film form.

[0018] Still another advantage of the present invention is that a phasechange or softening at the operating temperatures maximizes interfacialsurface wetting.

[0019] Still another advantage of the present invention is that lowapplication pressure without added heat allows for hand mounting duringfield rework and processor upgrades.

[0020] Still another advantage of the present invention is that theassembly process associated with thermal grease is eliminated but anequivalent thermal performance is maintained.

[0021] Still another advantage of the present invention system assemblycost is minimized by allowing for pre-attachment to a heat sink or CPU.

[0022] Still another advantage of the present invention is that thematerial softens and conforms to surface roughness or concavity atoperating temperature.

[0023] Still another advantage of the present invention is that thematerial operates at low clip pressures (5 to 10 psi).

[0024] Still another advantage of the present invention is that thematerial can be applied and repositioned with thumb pressure allowingfor easy field service.

[0025] Still another advantage of the present invention is that thematerial allows for vertical mounting due to its cohesive properties.

[0026] Still other benefits and advantages of the invention will becomeapparent to those skilled in the art upon a reading and understanding ofthe following detailed specification.

BRIEF DESCRIPTION OF THE FIGURES

[0027] The invention may take form in various components andarrangements of components, and in various steps and arrangements ofsteps. The drawings are only for purposes of illustrating a preferredembodiment and are not to be construed as limiting the invention.

[0028]FIG. 1 is a schematic view of a heat sink, heat source, andintermediate thermally conducting film prior to assembly, according tothe present invention;

[0029]FIG. 2 is a side sectional view of a first embodiment of amulti-layer strip comprising the film of FIG. 1;

[0030]FIG. 3 is a side sectional view of a second embodiment of amulti-layer strip;

[0031]FIG. 4 is a side sectional view of a further embodiment of amulti-layer strip;

[0032]FIG. 5 is a schematic side sectional view of a heat sink with themulti-layer strip of FIG. 2 attached;

[0033]FIG. 6 is a side sectional view of the heat sink, heat source andattached thermally conducting film of FIG. 1; and

[0034]FIG. 7 is a plot of thermal impedance versus mounting pressure forthree interface materials.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0035] With reference to FIG. 1, a thermally conductive, interfacematerial A in the form of a film or layer 10 provides a thermalinterface between an active device or heat source 12, such as amicroprocessor power supply assembly, and a heat sink 14, such as ablock of heat transmissive material, to facilitate heat transfer fromthe device 12 to the heat sink 14. It will be appreciated that the heatsource or device 12 can be any type of semiconductor device or powersupply assembly that generates excess heat in its operation, which heatif not removed, may damage the device or impair operation of the device.

[0036] The film 10 is preferably of from about 0.025 to 2.5 millimetersin thickness. The film thickness can be further increased, if desired,to accommodate certain application requirements, such as larger spacingcharacteristics in electronics or power supply cooling application.

[0037] The interface material A consists of a mixture of a phase changesubstance and a thermally conductive filler. The interface material Ahas a sufficient cohesive strength to allow handling in a roll form oras pre-cut pieces. The design of the product allows the use of die-cutparts mounted to a bandoleer web to supply continuous parts to a manualor automated part dispensing or “pick and place” part applicationprocess.

[0038] With reference also to FIGS. 2-4, the material A is preferablysupplied in the form of a multi-layer strip in which the film 10 of theinterface material is sandwiched between layers of adhesive and/orreleasable protective liners. FIG. 2 shows a first embodiment of amulti-layer strip 20 in which a protective liner 22 is supplied on oneor more sides of the film 10 of thermally conductive material A. Theprotective liner preferably comprises a coated substrate, such as SCKpolyethylene-coated paper (e.g., PN 907826, 20″, or 909785, 24″),polyethylene or polyester film, coated with a release coating, such as apolydimethyl siloxane, fluorosilicone, or non-silicone release coating.Examples of such laminates include blue poly 2.5 mil 2S PN 9099037. Oneor both sides of the liner substrate may be coated with release coatingas desired. The protective liner protects the film of thermallyconductive material against damage prior to application to the heat sinkor active device. The liner 22 is peeled off prior to use.

[0039] With reference to FIG. 3, a second embodiment of a multi-layerstrip 30 includes first and second liner layers 22 and 34 which form theoutermost layers of the strip 30. Intermediate between the film 10 ofthermally conductive material and one or more of the protective layers34 is a layer of adhesive 36 to aid in attachment of the film to theheat sink 14 or power supply assembly 12. The adhesive is preferably apressure sensitive adhesive, which permits the thermally conductive filmto be attached to a heat sink or to a power supply with minimalpressure, typically less than 10 psi, and without the need for heat.Where the adhesive is not employed, the thermally conductive film 10 isapplied to the heat sink or to the power supply by providing a smallamount of heat to the layer.

[0040] With reference to FIG. 4, a third embodiment of a multi-layerstrip 40 includes a reinforcement layer 42 between the thermallyconductive film 10 and adhesive layer 36. The reinforcement layer isprovided to improve the mechanical strength of the film. Thereinforcement layer may include a polymeric film, woven or non-wovencloth, such as glass cloth (formed from fiberglass), or a metallic film,such as aluminum. Alternatively, reinforcement materials, such as fibersor woven cloth, may be embedded in the thermally conductive film 10itself.

[0041] It should be readily appreciated that other configurations of themulti-layer strip are also possible depending on whether the film 10 isto be attached to one or the other or both of the heat sink 14 and themicroprocessor 12 prior to their shipment, and whether the attachment isto take place in the field, where heat for joining the film to the twoparts, 12, 14, is not readily available, and thus an adhesive layer, orlayers, is desired. For example, if the strip is to be attached to bothparts 12, 14, in the field, the strip may include two layers ofadhesive, one for attaching the film to the heat sink, the other forattaching the film to the power assembly.

[0042] With reference to FIG. 5, a multi-layer strip 20 of the typeillustrated in FIG. 2 is shown mounted to a heat sink (e.g., byapplication of pressure and/or heat). The protective layer 22 remains inplace until it is desired to attach the heat sink to a microprocessor 12(or to a power transistor or other heat-generating device).

[0043] With reference now to FIG. 6, the protective layer 22 has beenremoved from the multi-layer strip, and the exposed side of thethermally-conductive film 10 has been attached to the microprocessor 12.

[0044] During use, the heat generated by the microprocessor warms thethermally conductive film 10. The film undergoes a softening or phasechange at or just below the operating temperature of the microprocessor,allowing wet-out of the heat sink and microprocessor surfaces by thethermally conductive material A. This results in the elimination ofthermally insulating air pockets. After initial wetting, the material Aproceeds to transfer the heat generated by the microprocessor 12 to theheat sink 14.

[0045] The thermal performance of the thermally conductive film 10matches that of ceramic filled greases commonly used in the industry.However, the film retains a relatively high melt viscosity to eliminateexcessive flow and dripping from vertically mounted assemblies. Duringthermal cycling (on/off switching of the heat generating device 12) thefilm 10 maintains interfacial contact and excellent thermal performance.

[0046] The specific formulation of the film 10 is preferably selectedaccording to the conditions to which the film is to be exposed (e.g.,operating temperature, temperature cycling characteristics, and thelike). This allows customized adjustment and control for viscosity,thermal conductivity, and heat melt/flow properties to allow preciseperformance matching to various applications or requirements.

[0047] The film material A is composed of two elements, namely, athermally conductive filler and a phase change material. The phasechange material is a substance or mixture that undergoes a phase changeat, or just below, a selected operating temperature. The thermallyconductive filler increases the thermal conductivity of the phase changematerial and is preferably selected from a variety of materials having abulk thermal conductivity of between about 0.5 and 1000.0 Watts/meter-Kas measured according to ASTM D1530. Examples of suitable conductivefillers include, but are not limited to, boron nitride, aluminum oxide,nickel powder, copper flakes, graphite powder, powdered diamond, and thelike. Preferably, the particle size of the filler, the particle sizedistribution, and filler loading (concentration in the film) areselected to maximize packing and thus produce the most efficient thermalconductance. Preferably, the particle size of the filler is betweenabout 2 and 100 microns.

[0048] The phase change substance is a mixture of two or more compatiblecomponents or materials that undergoes a reversible solid-liquid phasechange at the operating temperature of the heating device. The viscosityof the phase change substance at the melting temperature is low enoughto completely wet-out the heat sink/power device interface but highenough to prevent exudation and loss of contact. The viscosity of thephase change substance at the operating temperature of themicroprocessor or power supply assemblies (typically operating in atemperature range from. 50° C. to 100° C.) is preferably between 1 and100 poise and more preferably from 5-50 poise. More preferably, thephase change substance maintains a viscosity of between 5 and 50 poiseover the temperature range of 60-120° C. and has a melting point in therange of 30-120° C.

[0049] When cooled below its melting point, the phase change substancesolidifies without a significant change in volume, thereby maintainingintimate contact between the heat sink 14 and the power device 12.

[0050] The first component of the phase change substance is a polymercomponent which includes a polymer. Suitable polymers include single ormulti-component elastomers, consisting of one or more of the following:silicone, acrylic, natural rubber, synthetic rubber, or otherappropriate elastomeric materials. Examples of such elastomers includestyrene butadiene rubbers, both di-block and tri-block elastomers (e.g.,Kraton® from Shell Chemicals) nitrile, natural rubber, polyester resins,combinations thereof, and the like, where the Mooney viscosity can rangeup to 40 ML4. Examples of suitable acrylic polymers include Aeroset1085, Aeroset 414, Aeroset 1845, Aeroset 1081, and Aeroset 1452,obtainable from Ashland Chemicals.

[0051] The second component of the phase change substance is a meltingpoint component. This component influences the melting point of thephase change substance for achieving a melting point of the film ataround the operating temperature. Examples of suitable melting pointcomponents include C₁₂-C₁₆ alcohols, acids, esters, and waxes, lowmolecular weight styrenes, methyl triphenyl silane materials,combinations thereof, and the like. Suitable C₁₂-C₁₂-C₁₆ acids andalcohols include myristyl alcohol, cetyl alcohol, stearyl alcohol,myristyl acid, and stearic acid. Preferred waxes includemicrocrystalline wax, paraffin waxes, and other wax-like compounds, suchas cyclopentane, heceicosyl; 2-heptadecanone; pentacosaneyl; silicicacid, tetraphenyl ester; octadecanoic acid; 2-[2-[2-(2hydroxyethoxy)ethoxy] ethoxy] ethyl ester; cyclohexane, docosyl; polystyrene;polyamide resins; disiloxane 1,1,1, trimethyl-3,3; and triphenyl silane.

[0052] The polymer component provides the phase change material withbody (viscosity) to prevent the melting point component and filler fromflowing out from between the heat sink and the microprocessor heatsource. It thus acts as a viscosity controller. It also provides thefilm 10 with flexibility, handleability, and other film formingcharacteristics at ambient temperatures. Without the polymer componentpresent, the melting point component would be brittle and tend tofracture and disintegrate at room temperature.

[0053] The melting point component melts at around the operatingtemperature and dissolves the polymer component in the melting pointcomponent. The viscosity of the liquefied melting point component dropsas the polymer component dissolves in it. The resulting viscosity issufficient for the material A to flow and wet the adjacent surfaces ofthe heat sink 14 and microprocessor heat source 12, creating thermalconduction paths and excellent thermal contact. Surface discontinuitiesin the heat sink and microprocessor heat source are filled with thematerial A. However, the viscosity is not so low that the material Aflows out from between the parts 12, 14. To ensure that the thermalinterface material has a relatively broad melting point, yet does notflow too readily at room temperatures, a combination of melting pointcomponents having differing melting points may be employed. For example,a combination of a C₁₆ component, such as cetyl alcohol, with a C₁₄component, such as myristyl alcohol, yields a thermal interface materialwith good handling properties.

[0054] Preferably, the solubility parameter (δ) of the polymer componentis within +1 and −1 of the solubility parameter(s) of the melting point,wax like component(s). This provides a level of compatibility betweenthe liquefiable components.

[0055] Preferably, the material A comprises:

[0056] 1) from 10-80% polymer, more preferably 10-70%, most preferablyfrom about 15 to about 50% polymer by weight;

[0057] 2) from 10-80% filler, more preferably 10-70%, most preferably,from about 15 to about 60% filler by weight; and

[0058] 3) from 10-80% melting point component, more preferably 15-70%,most preferably, from about 20% to about 60% melting point component byweight.

[0059] The material A may also contain other ingredients, such ascolorants, e.g., for identifying the particular properties of thematerial; antioxidants, for improving storage properties; wettingagents, for improving contact with microprocessor components, and thelike.

[0060] To prepare the films 10, the components of the phase changematerial (polymer component and melting point component) are mixed withthe filler. To improve the spreading characteristics of the material A,a processing aid, such as a solvent may be added to the mixture.Suitable solvents include low boiling aromatic and aliphatic compounds,such as toluene, benzene, xylene, heptane, mineral spirits, ketones,esters, alcohols, such as isopropyl alcohol, and mixtures thereof. Aparticularly preferred solvent is toluene, or a mixture of toluene andisopropyl alcohol. The isopropyl alcohol assists in dissolving themelting point component in the mixture.

[0061] The mixture is heated to about 50° C. to disperse the componentsand then dried to form the film 10 on one of the release liners 22.During this stage, the solvent evaporates. Optionally, a reinforcinglayer 42 is then laminated to the thermal interface material.Alternatively, reinforcing materials, such as fibers, may be mixed withthe thermal interface material prior to drying the film on the releaseliner.

[0062] One or more layers of adhesive are then optionally applied to thefilm 10 (or to the reinforcing layer) and a second release liner appliedto the adhesive. Alternatively, the film is applied directly to amicroprocessor power assembly or heat sink.

[0063] Suitable adhesives for the adhesive layer include Dow PSAadhesives 750D1 and 6574 and Ashland 414. The adhesive may be coated toa thickness of about 0.0002-0.0004 inches.

[0064] In another alternative embodiment, the adhesive is first appliedto the second release liner. The release liner with the film and therelease liner with the adhesive are then sandwiched together, optionallywith application of heat, to bond the adhesive layer to the thermalinterface material. A reinforcing material 42, such as glass cloth, maybe laminated to the adhesive layer or to the thermal interface material,prior to sandwiching the adhesive layer and thermal interface materialtogether.

[0065] The multi-layer strip thus formed may be supplied on a reel orsectioned into suitably sized pieces.

[0066] While not intending to limit the scope of the invention, thefollowing examples provide suitable compositions for the thermalinterface material A and the properties thereof.

EXAMPLES

[0067] In the following examples, components were obtained, as follows:

[0068] Melting Point components:

[0069] Myristyl alcohol (a C₁₄ alcohol), cetyl alcohol (a C₁₆ alcohol,sold under the tradename Lorol C₁₆), stearyl alcohol, myristyl acid, andstearic acid were obtained from Aldrich Chemical or Henkel Chemicals.

[0070] Petroleum waxes were obtained from Bareco, including BarecoSC4095, Bareco SC5050, Bareco 5051, Bareco 6513, and Ultraflex.

[0071] Low melting aromatic hydrocarbons were obtained from Hercules,such as Piccolastic A-50, A-25, and A75.

[0072] Polymer Components:

[0073] Several acrylic polymers were obtained from Ashland Chemicalincluding Aeroset 1845, Aeroset 1085, Aeroset 1081, Aeroset 414, andAeroset 1452.

[0074] Natural Rubber was obtained.

[0075] A di-block copolymer of styrene and butadiene was obtained fromShell Chemical.

[0076] Di-block copolymers of styrene and EP rubber were obtained fromShell, such as Kraton 1107, 1102, 1652.

[0077] Low melting point aromatic hydrocarbon resins were obtained fromHercules, such as Piccolite A50.

[0078] Filler materials:

[0079] Boron Nitride was obtained from Advanced Ceramics. Alumina(Al₂O₃) was obtained from Alcoa Aluminum.

[0080] Other Additives

[0081] Irganox 330, and Irganox 1010, both antioxidants, were obtainedfrom Ciba Geigy.

[0082] A wetting agent, KR38S, was obtained from Kendrich.

[0083] Pigments were added in some examples for aesthetic purposes.

Example 1

[0084] To prepare a thermal interface material A, Aeroset 1845, myristylacid, and boron nitride were combined in a mixture with toluene in thefollowing amounts: Ingredient Weight % Purpose of the Mixture Aeroset1845 40 polymer component Boron Nitride Powder 20 filler materialMyristyl Acid 20 melting point component Toluene 20 solvent

[0085] This mixture was heated to 500 and mixed until homogeneous. Themixture was then dried at 100° C. for 5 minutes on a release liner toform a film 10. The dry thickness of the film (measured after removal ofthe release liner) was 0.00511 (0.127 mm), as were the films of Examples2-17 below.

Example 2

[0086] To prepare a thermal interface material, Aeroset 414, myristylacid, and boron nitride were combined in a mixture with toluene in thefollowing amounts: Ingredient Weight % Purpose of the Mixture Aeroset414 40 polymer component Boron Nitride Powder 20 filler materialMyristyl Acid 20 melting point component Toluene 20 solvent

[0087] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 3

[0088] Aeroset 1085, myristyl acid, and boron nitride were combined in amixture with toluene in the following amounts: Ingredient Weight %Purpose of the Mixture Aeroset 1085 40 polymer component Boron NitridePowder 20 filler material Myristyl Acid 20 melting point componentToluene 20 solvent

[0089] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 4

[0090] Aeroset 1845, myristyl acid, and alumina were combined in amixture with toluene in the following amounts: Ingredient Weight %Purpose of the Mixture Aeroset 1845 40 polymer component Alumina Powder20 filler material Myristyl Acid 20 melting point component Toluene 20solvent

[0091] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 5

[0092] Aeroset 1845, cetyl alcohol, and boron nitride were combined in amixture with toluene in the following amounts: Ingredient Weight %Purpose of the Mixture Aeroset 1845 40 polymer component Boron NitridePowder 20 filler material Cetyl alcohol 20 melting point componentToluene 20 solvent

[0093] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 6

[0094] Aeroset 1845, myristyl alcohol, and boron nitride were combinedin a mixture with toluene in the following amounts: Ingredient Weight %Purpose of the Mixture Aeroset 1845 40 polymer component Boron NitridePowder 20 filler material Myristyl alcohol 20 melting point componentToluene 20 solvent

[0095] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 7

[0096] Aeroset 1845, stearyl alcohol, and boron nitride were combined ina mixture with toluene in the following amounts: Ingredient Weight %Purpose of the Mixture Aeroset 1845 40 polymer component Boron NitridePowder 20 filler material Stearyl alcohol 20 melting point componentToluene 20 solvent

[0097] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 8

[0098] Aeroset 1081, myristyl acid, and boron nitride were combined in amixture with toluene at the ratios: Ingredient Weight % Purpose of theMixture Aeroset 1081 40 polymer component Boron Nitride Powder 20 fillermaterial Myristyl Acid 20 melting point component Toluene 20 solvent

[0099] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 9

[0100] Natural rubber, Bareco SC5050, Piccolastic A50, and boron nitridepowder were combined with toluene in the following amounts: IngredientWeight % Purpose of the Mixture Natural rubber 10 polymer componentBoron Nitride Powder 30 filler material Bareco SC 5050 20 melting pointcomponent Toluene 30 solvent Piccolastic A50 10 melting point component

[0101] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 10

[0102] Natural rubber, Bareco SC5050, Piccolastic A50, and boron nitridepowder were combined with toluene as follows: Ingredient Weight %Purpose of the Mixture Natural rubber 20 polymer component Boron NitridePowder 10 filler material Bareco SC5050 20 melting point componentToluene 30 solvent Piccolastic A50 20 melting point component

[0103] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 11

[0104] Natural rubber, Bareco SC5050, Piccolastic A25, and boron nitridepowder were combined with toluene, as follows: Ingredient Weight %Purpose of the Mixture Natural rubber 10 polymer component Boron NitridePowder 30 filler material Bareco SCS050 20 melting point componentToluene 30 solvent Piccolastic A25 10 melting point component

[0105] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 12

[0106] Natural rubber, Bareco SC5050, and boron nitride powder werecombined with toluene as follows: Ingredient Weight % Purpose of theMixture Natural rubber 20 polymer component Boron Nitride Powder 40filler material Bareco SC5050 10 melting point component Toluene 30solvent

[0107] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 13

[0108] Kraton 1107, Bareco SC5050, Piccolastic A50, and Boron Nitridewere combined with toluene as follows: Ingredient Weight % Purpose ofthe Mixture Kraton 1107 10 polymer component Boron Nitride Powder 30filler material Bareco SC5050 20 melting point component Toluene 30solvent Piccolastic A50 10 melting point component

[0109] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 14

[0110] Kraton 1102, Bareco SC5050, Piccolastic A50, and boron nitridewere combined as follows: Ingredient Weight % Purpose of the MixtureKraton 1102 10 polymer component Boron Nitride Powder 30 filler materialBareco SC5050 melting point component Toluene 30 solvent Piccolastic A5010 melting point component

[0111] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 15

[0112] Kraton 1652, Bareco SC5050, Piccolastic A50, and boron nitridewere combined with toluene as follows: Ingredient Weight % Purpose ofthe Mixture Kraton 1652 10 polymer component Boron Nitride Powder 30filler material Bareco SC5050 20 melting point component Toluene 30solvent Piccolastic A50 10 melting point component

[0113] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 16

[0114] Kraton 1107, Bareco SC5050, and Boron Nitride were combined withtoluene as follows: Ingredient Weight % Purpose of the Mixture Kraton1107 10 polymer component Boron Nitride Powder 30 filler material BarecoSC5050 20 melting point component Toluene 30 solvent

[0115] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 17

[0116] Natural Rubber, Bareco SC5050, and alumina powder were combinedwith toluene as follows: Ingredient Weight % Purpose of the MixtureNatural rubber 10 polymer component Alumina 30 filler material BarecoSC5050 20 melting point component Toluene 40 solvent

[0117] This mixture was heated, coated and dried on a release liner,using the method of Example 1.

Example 18

[0118] Ashland adhesive, Aeroset 1081, Lorol C₁₆ (cetyl alcohol),isopropyl alcohol, boron nitride, Irganox 330 (an antioxidant, obtainedfrom Ciba Geigy), Irganox 1010(an antioxidant, obtained from CibaGeigy), KR38S (a wetting agent, obtained from Kendrich), and pigments(for aesthetic purposes), were combined in a mixture as listed belowwith toluene at the following ratios: Ingredient Weight Percent Irganox330  0.32% Boron Nitride 23.76% Isopropyl Alcohol 22.45% Irganox 1010 0.32% KR 38S  0.24% Toluene  4.82% Pigment Red (UDC Red)  0.08% PigmentYellow (UDC yellow)  0.48% Cetyl Alcohol 17.11% Cetyl Alcohol  9.51%Aeroset Adhesive 1081 Adhesive 20.91   1081

[0119] This mixture was heated to 50° C. and mixed until a homogeneoussolution developed. The cetyl alcohol was added in two stages, althoughthe total amount may also be added at one time. The solution was thencoated onto a paper previously coated with a silicone release film. Thecoating was dried at 100° C. for 5 minutes. The dry thickness was 0.003″thick. The thermal interface material thus formed was removed from theliner and tested in an Anter “Unitherm™” thermal test apparatus, model2021 SX67 according to ASTM D1530. The thermal resistance of the samplewas 0.03° C.-in²/W. Thermal conductivity was 1.2 W-M/K.

Example 19

[0120] Aeroset 1081, Lorol C16 alcohol, and boron nitride were combinedin a mixture with other ingredients and toluene at the following ratios:Component Percent of total Aeroset 1081 20.973 Isopropyl alcohol 22.523Toluene 4.493 Boron Nitride 23.84 Cetyl Alcohol 26.697 Irganox 330 0.323Irganox 1010 0.323 KR38S 0.27 UCD Yellow 0.476 UCD Red 0.081

[0121] The mixture was heated to 50° C. and mixed until homogeneous.This solution was then coated onto a liner paper coated with siliconerelease. This was dried at 100° C. for 5 minutes. The dry thickness was0.003″ thick. The thermal interface material was removed from the linerand tested in an Anter “Unitherm™” thermal test apparatus, model 2021SX67 according to ASTM D1530. The thermal resistance of the sample was0.03° C.-in²/W. Thermal conductivity was 1.2 W-M/K.

Example 20

[0122] An adhesive (Dow PSA 750D1) was coated onto a liner sheet (Furonproduct number 9022) at 0.0003″ thick. The PSA coated liner was thenlaminated to a sheet of woven fiberglass as a reinforcing material(Product #106 from BGF industries). A liner sheet with a thermalinterface material was prepared according to the method of Example 19.Then the polymeric coated sheet of Example 19 and the fiberglasslaminated with the PSA coated liner were heated and laminated togetherat 130° F. to provide a multiple layer strip in the following order:

[0123] Furon liner sheet,

[0124] PSA adhesive,

[0125] fiberglass sheet,

[0126] thermal interface material, and

[0127] release-coated liner.

[0128] The thermal interface material laminated to glass cloth(fiberglass) was removed from the two liner sheets and tested in anAnter “Unitherm™” thermal test apparatus, model 2021 SX67 according toASTM D1530. The thermal resistance of the sample was 0.04° C.-in²/W.Thermal conductivity was 1.1 W-M/K.

Example 21

[0129] An adhesive (Dow PSA 750D1) was coated onto a liner (Furonproduct number 9022) at 0.0003″ thick. The PSA coated sheet was thenlaminated to fiberglass (fiberglass #106 from BGF industries). A linersheet coated with thermal interface material was prepared according tothe method of Example 19. Then, the polymeric coated sheet of Example 19and fiberglass laminated with the PSA coated liner were heated andlaminated together at 130° F. The thermal interface material laminatedto glass cloth was removed from the liners and tested in an Anter“Unitherm™” thermal test apparatus, model 2021 SX67 according to ASTMD1530. The thermal resistance of the sample was 0.04° C.-in²/W. Thermalconductivity was 1.1 W-M/K.

Example 22

[0130] An adhesive (Dow PSA 6574) was coated onto a liner (Furon productnumber 9022) at 0.0003″ thick. The PSA coated sheet was then laminatedto fiberglass (fiberglass #106 from BGF industries). A liner sheetcoated with thermal interface material was prepared according to themethod of Example 19. Then, the polymeric coated sheet of Example 19 andfiberglass laminated with the PSA coated liner were heated and laminatedtogether at 130° F. The thermal interface material laminated to glasscloth was removed from the liners and tested in an Anter “Unitherm™”thermal test apparatus, model 2021 SX67 according to ASTM D1530. Thethermal resistance of the sample was 0.04° C.-in²/W. Thermalconductivity was 1.1 W-M/K.

Example 23

[0131] An adhesive (Dow PSA 6574) was coated onto a liner (Furon productnumber 750D1) at 0.0003″ thick. The PSA coated sheet was then laminatedto 0.002″ thick aluminum foil. A liner sheet with thermal interfacematerial was prepared according to the method of Example 19. Then, thepolymeric coated sheet of Example 19 and aluminum foil laminated withthe PSA coated liner were heated and laminated together at 130° F. Thethermal interface material laminated to glass cloth was removed from theliners and tested in an Anter “Unitherm™” thermal test apparatus, model2021 SX67 according to ASTM D1530. The thermal resistance of the samplewas 0.025° C.-in²/W. Thermal conductivity was 1.5 W-M/K.

Example 24

[0132] An adhesive (Ashland 414) was coated onto a liner (Furon linerproduct number 1018) at 0.0002″ thick. The adhesive coated liner wasthen laminated to fiberglass (fiberglass #106 from BGF industries). Aliner sheet coated with thermal interface material was preparedaccording to the method of Example 19. Then, the polymeric coated sheetof Example 19 and fiberglass laminated with the PSA coated liner wereheated and laminated together at 130° F. The thermal interface materiallaminated to glass cloth was removed from the liners and tested in anAnter “Unitherm™” thermal test apparatus, model 2021 SX67 according toASTM D1530. The thermal resistance of the sample was 0.04° C.-in²/W.Thermal conductivity was 1.1 W-M/K.

Example 25

[0133] The films produced in examples 1-17 were tested for chemical andphysical properties. Table 1 summarizes the properties for each of theexamples. As can be seen from Table 1, the melting point of the file canbe adjusted by selecting the components of the melting component.Thermal impedance and thermal conductivity were measured on liner freesamples of the film using Anter “Unitherm™” thermal test apparatus,model 2021 SX67, according to ASTM D1530. Differential ScanningCalorimetry (DSC) was used to determine the melting point of thecompound. Thermal Thermal Resistance DMA Melting Impedance ThermalPentium Viscosity @ Solubility Solubility Point (° C. Conductivity Pro100° C. Parameter Parameter Example DSC ° C. in²/W) (W-m/K) (° C./W) (Pa· S) Waxδ Polymer δ 1 58 .07 0.8 0.30 10.1 10.5 2 58 .08 0.8 0.28 5010.1 10.5 3 58 .07 0.8 0.22 10.1 10.5 4 58 .07 0.7 0.29 10.1 10.5 5 50.07 0.8 0.21 15 10.7 10.5 6 40 .07 0.8 0.19 10 10.5 10.5 7 60 .07 0.80.27 10.5 10.5 8 58 .07 0.8 0.30 10.4 10.5 9 45 .07 0.8 0.35 7.4 7.4 1045 .10 0.5 0.33 7.4 7.4 11 45 .07 0.8 0.33 7.4 7.4 12 45 .07 1.4 0.347.4 7.4 13 47 .07 0.8 0.30 7.4 7.4 14 47 .07 0.8 0.28 7.4 7.4 15 47 .070.8 0.27 7.4 7.4 16 45 .07 0.8 0.29 7.4 7.4 17 45 .07 0.8 0.35 7.4 7.4

Example 26

[0134] Mounting pressure for various films was calculated using thefollowing formula: $P = \frac{T \times N}{0.2 \times D \times A}$

[0135] where

[0136] N=Number of fasteners

[0137] D=Fastener diameter (inches)

[0138] A=Surface contact area (sq. in.)

[0139]FIG. 7 shows a plot of thermal impedance versus the mountingpressure for three different materials. The first two are a siliconecoated fabric using Bergquist SP 400, a silicone coated polyimide(Kapton®, prepared according to U.S. Pat. No. 4,574,879 and the third isthe film of Example 6 of this application. As can be seen from FIG. 7,the film of Example 6 has low thermal impedance over the entire range ofmounting pressures.

[0140] The invention has been described with reference to the preferredembodiments. It should be apparent that modifications and alterationswill occur to others upon a reading and understanding of the precedingspecification. It is intended that the invention be construed asincluding all such alterations and modifications insofar as they comewithin the scope of the appended claims or the equivalents thereof.

Having thus described the preferred embodiments, the invention is nowclaimed to be:
 1. A thermal interface material which undergoes a phasechange at microprocessor operating temperatures to transfer heatgenerated by a heat source to a heat sink, the material comprising: aphase change substance which softens at about the operating temperatureof the heat source, the phase change substance including: a polymercomponent, and a melting component mixed with the polymer component,which modifies the temperature at which the phase change substancesoftens; and a thermally conductive filler dispersed within the phasechange substance.
 2. The thermal interface material of claim 1, whereinthe phase change substance has a viscosity of from 1 to 100 poise at theoperating temperature of the heat source.
 3. The thermal interfacematerial of claim 1, wherein the phase change substance has a viscosityof from 5 to 50 poise in the temperature range of 60 to 120° C.
 4. Thethermal interface material of claim 1, wherein the phase changesubstance has a melting point of 30-120° C.
 5. The thermal interfacematerial of claim 1, wherein the polymer component includes an elastomerselected from the group consisting of silicone, acrylic polymers,natural rubber, synthetic rubber, and combinations thereof.
 6. Thethermal interface material of claim 1, wherein the polymer component hasa Mooney viscosity of up to 40 ML4.
 7. The thermal interface material ofclaim 1, wherein the melting point component is selected from the groupconsisting of C₁₂-C₁₆ alcohols, acids, esters, petroleum waxes, wax-likecompounds, low molecular weight styrenes, methyl triphenyl silanematerials, and combinations thereof.
 8. The thermal interface materialof claim 7, wherein the melting point component is a C₁₂-C₁₆ alcohol oracid selected from the group consisting of myristyl alcohol, cetylalcohol, stearyl alcohol, myristyl acid, stearic acid, and combinationsthereof.
 9. The thermal interface material of claim 7, wherein themelting point component is a wax or a waxlike compound selected from thegroup consisting of microcrystalline wax, paraffin waxes, cyclopentane,heceicosyl, 2-heptadecanone, pentacosaneyl, silicic acid, tetraphenylester, octadecanoic acid, 2-[2-[2-(2hydroxyethoxy) ethoxy]ethoxy]ethylester, cyclohexane docosyl, polystyrene, polyamide resins, disiloxane1,1,1, trimethyl-3,3, triphenyl silane, and combinations thereof. 10.The thermal interface material of claim 1, wherein the polymer componenthas a solubility parameter which is within +1 and −1 of the solubilityparameter of the melting point component.
 11. The thermal interfacematerial of claim 1, wherein: the polymer component is at aconcentration of from 10-80% by weight; the filler is at a concentrationof from 10-80% by weight; and the melting point component is at aconcentration of from 10-80% by weight.
 12. The thermal interfacematerial of claim 11, wherein: the polymer component is at aconcentration of from 10-70% by weight; the filler is at a concentrationof from 10-70% by weight; and the melting point component is at aconcentration of from 15-70% by weight.
 13. The thermal interfacematerial of claim 1, wherein the thermally conductive filler has a bulkthermal conductivity of between about 0.5 and 1000 watts meter perdegree Kelvin.
 14. The thermal interface material of claim 1, whereinthe thermal interface material has a thermal conductivity of at least0.8 watts meter per degree Kelvin.
 15. The thermal interface material ofclaim 1, wherein the thermally conductive filler is selected from thegroup consisting of boron nitride, aluminum oxide, nickel powder, copperflakes, graphite powder, powdered diamond, and combinations thereof. 16.The thermal interface material of claim 1, wherein the thermallyconductive filler has an average particle size of from about 2 to 100microns.
 17. A multi-layer strip comprising: a first layer of a thermalinterface material for thermally connecting a heat source with a heatsink, including: a polymer component, a melting point component mixedwith the polymer component in sufficient quantity to adjust thesoftening temperature of the interface material to about the operatingtemperature of the heat source, and a thermally conductive filler mixedwith the melting point component and the polymer component; and a secondlayer disposed on a side of the thermal interface material, the secondlayer including at least one of: a protective releasable liner, and alayer of an adhesive material.
 18. The multi-layer strip of claim 17,wherein the second layer includes a protective releasable liner and thestrip further comprises: a layer of an adhesive material disposed on asecond side of the thermal interface material.
 19. The multi-layer stripof claim 18, further including: a second protective release linerdisposed on the layer adhesive material.
 20. The multi-layer strip ofclaim 17, further including a reinforcing material in contact with theinterface material.
 21. The multi-layer strip of claim 20, wherein thereinforcing material is selected from the group consisting of fiberglassand aluminum foil.
 22. The multi-layer strip of claim 17, wherein theprotective liner includes a substrate coated with a release coating. 23.A method of providing a thermal interface between a heat source and aheat sink, the method comprising: interposing a thermal interfacematerial between the heat source and heat sink which softens at aboutthe operating temperature of the heat source to provide a thermalinterface between the heat source and the heat sink during operation ofthe heat source, the thermal interface material including: a polymercomponent, a melting component for modifying the temperature at whichthe thermal interface material softens, and a thermally conductivefiller mixed with the polymer component and the melting point component.24. The method of claim 23, further including: adhering the thermalinterface material to one of the heat source and the heat sink byapplication of heat.
 25. The method of claim 23, further including:adhering the thermal interface material to one of the heat source andthe heat sink with a layer of an adhesive material.